数控课程设计说明书

数控加工课程设计说明书一、分析零件图纸,拟定总体加工方案（一）、图纸分析:该图是一复杂轴类零件,零件部分地方较为复杂,部分加工精度较高,采用数控车削加上钻削、滚齿、插齿综合完毕。该零件由外圆柱面、孔、倒角、内齿轮,齿轮轴、槽、阶梯组成。其中零件最大外径为19mm,长度为104mm.选择毛坯尺寸为114x22mm的棒料。（二）、精度等级、表面粗糙度分析:考虑到左右两端齿轮齿面粗糙度1.6,滚齿机滚齿后要倒角磨齿；外圆表面粗糙度规定最高为0.8,尺寸精度也易于达成,所以外圆精车即可达成规定。同轴度及各圆跳度都规定要装夹次数减少。所以,外圆以两顶尖定位,一次装夹完毕粗精加工。为满足同轴度规定,打孔时应夹外径为13.9的外圆。（三）、材料和热解决分析:零件材料为31CrMoV9是齿轮钢,预备热解决为调质,回火温度600℃——630℃。最终热解决为渗氮,HV900。（四）、总体方案:先对毛坯预备热解决（调质解决）；用数控车床粗精车两端面打中心孔,再以两中心孔定位,粗车外圆轮廓,精车右端外圆轮廓,切槽。再以外径为13.9的槽定位,粗精车左端外圆,钻铰孔、镗孔割内槽；最后再滚齿,插齿；最终热解决,再上磨齿机进行磨齿；完毕整个零件的加工。二、拟定加工工艺方案（一）装夹方式及量具选择:数控车床夹具使用三爪卡盘自动定心夹具及顶尖；Y3150E滚齿机使用专用夹具,插齿机使用专用夹具,磨齿机使用专用夹具。量具有游标卡尺,外径千分尺,百分表。（二）加工顺序:1.备料,下料尺寸ф22×106的棒料,预备热解决2.车,粗精车右端面,钻中心孔3.粗车，夹左端外圆顶中心孔定位，粗车右端外圆各部，留单边余量0.24、精车,夹左端外圆顶中心孔定位,精车右端外圆各部至图纸所示。5.切1.1mm宽的槽6、用3.5mm切槽刀切3.5mm处,4.6mm处以及12mm处,加之外径为13.9的T型槽至图纸所示。7、掉头夹直径12处外圆,粗精车左端端面及外圆8、钻镗直径为9的孔9、镗直径为12.5的孔。10、割宽5mm的内槽。11.钻直径5和4的顶孔。12.铣键槽13.滚齿机滚右端齿14.插齿机插内齿轮。15、倒角,倒棱16.最终热解决17、磨齿机磨齿18、终结检查（三）,切削用量选择（镗车削）数控车削加工中的切削用量涉及：背吃刀量
、主轴转速n或切削速度
、进给速度
或进给量f。这些参数均应在机床给定的允许范围内选取。车削用量的选择原则是粗车时,一方面考虑选择尽也许打的背吃刀量
,另一方面选择较大的进给量f,最后拟定一个合适的切削速度v。增大背吃刀量可使走刀次数减少,增大进给量f有助于断屑。精车时,加工精度和表面粗糙度规定较高,加工余量不大且较均匀,因此选择精车的切削用量时,应着重考虑如何保证加工质量,并在此基础上提高加工效率。因此,精车时应选用较小的背吃刀量
和进给量f,并选用性能高的刀具材料和合理的几何参数,以尽也许提高切削速度v.背吃刀量的拟定在工艺系统刚度和机床功率允许的情况下,应尽也许选择较大的背吃刀量,以减少进给的次数。当零件精度规定较高时,则应考虑留出精车余量,其所留的精车余量比一般普通车削时所留余量小,常取0.1~0.5mm。（2）进给量的拟定

式中,f进给量,粗车时一般取为0.3~0.8mm/r,精车时常取0.1~0.3mm/r,切断时常取0.05~0.2mm/r。（3）主轴转速的拟定n（r/min）1.数控车削a.粗车端面取n=50m/minf=0.3mm/rb.精车端面取n=80m/minf=0.15mm/rb.粗车外轮廓,留单面余量0.2mm取n=50m/minf=0.3mm/rap=2mmc.精车外轮廓取n=80m/minf=0.15mm/rap=0.2mmd.切槽取n=60m/minf=0.1mm/rf.预钻孔Ф8mm及打中心孔取n=500r/minf=0.2mm/rg.镗孔取n=1500r/minf=0.2mm/r2.滚齿机滚齿Vc=0.7m/sf=1.5mm/r刀具明细表序号刀具名称刀具直径刀补值190°端面车刀D01293°偏头外圆车刀D0231.15mm割槽刀43.5mm割槽刀54mm割槽刀6高速钢钻头87镗刀8镗刀D0893mm的内切槽刀10滚刀D1011插齿刀D11三、数值换算1.公差对称化换算:直径公差带代号公差大小/mm上偏差下偏差对称化后尺寸12g70.018-0.006-0.02411.985100-0.19.9516h70.0180-0.01815.99115.50-0.315.3513.90-0.0313.88516.80-0.116.757.80.0507.82517h80.0180-0.01816.99116.40-0.0416.389H100.0580.05809.02911.50.3011.6530.50.3030.65601001.1590.0509.02511.50-0.111.452.相关节点坐标计算:如图所示:通过坐标标注,各节点坐标清清楚楚。3.刀位点坐标值的计算过程刀位点是指刀具的定位基准点。车刀的刀位点是刀尖或刀尖圆弧中心；钻头的刀位点是钻头顶点。各类数控机床的对刀方法是不完全同样的,这一内容将结合各类机床分别讨论。数控车床的刀位点是工件外形轮廓向外偏移一个刀具半径值四、数控的工艺卡片及加工程序O0001——车左端面打中心孔加工环节加工内容刀具主轴转速（m/min或r/min）进给量备注1粗车端面,留精加工余量0.2T01:90°端面车刀500.32精车端面至图纸规定T01800.153打中心孔T02:直径3.35中心钻5000.2O0002——车外轮廓加工环节加工内容刀具主轴转速（m/min或r/min）进给量备注1粗车外圆轮廓,留精加工余量0.2T01:93°偏头外圆车刀500.3G712精车外圆轮廓至图纸规定T01:93°偏头外圆车刀800.15G703切1.1mm宽槽T02:1.1mm割槽刀（右刀尖）600.14切3.5mm宽槽及4.6mm滚花槽T03:3.5mm割槽刀（右刀尖）600.15切T型槽及其他槽T04:4mm割槽刀（右刀尖）600.1O0003——精车左端端面,外圆,钻镗孔加工环节加工内容刀具主轴转速（m/min或r/min）进给量备注1粗车外圆轮廓,留精加工余量0.2T01:93°偏头外圆车刀500.3G712精车外圆轮廓至图纸规定T01:93°偏头外圆车刀800.15G703钻底孔T02:直径为8mm高速钢麻花钻5000.24镗孔T03:硬质合金内孔车刀5000.25镗直径为12.5mm的孔T04:硬质合金内孔车刀15000.26割内槽T05:硬质合金内切槽刀600.1程序代码如下:O0001N10G54F0.3S800M03M07T0101;工艺设定N20G50S2023；最高转速限制N30G96S50；恒线速度切削N40G0X24Z0.2；快速定位接近工件N50G1X-2；粗切端面N60G0X24Z1N80G96S80；精车恒线速度设定N90Z0N100G1X-2F0.15；精车端面N110G0X100Z150；返回换刀点N120T0202；换2号刀具N130G97S500；取消恒线速度,设定转速500r/min。N140X0Z5N150G1Z-3.35；钻中心孔N160G0Z5N170X100Z150N180M30；程序结束O0002N10G54F0.3S800M03M07T0101;工艺设定G50S2023；最高转速限制G96S50；恒线速度切削G0X24Z0.2；快速定位接近工件G1X-2；粗切端面G0X24Z1G96S80；精车恒线速度设定Z0G1X-2F0.15；精车端面N40G71U2R1；G71粗车轮廓循环N50G71P60Q170U0.4W0.2F0.3；粗车轮廓循环参数设定N60G0G42X8Z2F0.15；循环开始N70G1Z0N80X9.95Z-0.58N90Z-15.72N100G02X10.36Z-16.94R3N110G01X11.985Z-19N120Z-36.5N130X15.35N140X15.991Z-36.64N150W-7.825N160X19N170Z-106；循环结束N180G0X100Z150N190G96S80；恒线速度切削N200G70P60Q170；G70循环精车外轮廓N210G0X100Z150；返回换刀点N220T0202；换1.1mm切槽刀N230G96S60N240G0G40X13Z-27.5F0.1；取消刀补,快速定位N250G1X11.45N260G0X20N270G0X100Z150N280T0303;换3.5mm切槽刀N290G0X17Z-38.5;切3.5mm槽N300G1X-15.96N310G0X20N320Z-31.9；切4.6mm槽N332G1X11.9N340G0X14N345Z-40.8N350G1X11.5N355Z-31.9；切4.6mm槽结束N360G0X20N370G0X100Z150N380T0404；换4mm切槽刀N390G0X20Z-50.35N400G1X14.3；粗切直径为13.9的T型槽及宽12mm槽N410G0X20Z-53.5N420G1X14.3N430G0X20N435Z-53.5N440G1X14.3N450G0X20N451Z-57N452G1X14.3N453G0X20N455Z-60.6N460G1X14.3N470G0X20N475Z-69.5N480G1X17.2 ；T型槽粗切结束N490G0X20N495Z-72N500G1X17.2；粗切12mm槽N510G0X20N515Z-75N520G1X17.2N530G0X20N531Z-75N532G1X17.2N534G0X20N535Z-77.5N540G1X17.2；12mm槽粗车结束N550G0X20Z-75N560Z-45.5N570G1X19；精车T型槽N580X14.32Z-49.55N590G02X13.885Z-50.35R1.6N600G01Z-64.6N610G2X14.28Z-65.35R1.6N620G1X18.22Z-69.06N630G3X17.68Z-69.5R0.15；精车T型槽结束N640G1X16.75;精车12mm槽N645Z-77.5N650G0X100Z150N660M30;程序结束O0003N10G54F0.3S800M03M07T0101;工艺设定N20G50S2023；最高转速限制N30G96S50；恒线速度切削N40G71U2R1N50G71P60Q130U0.4W0.2F0.3;G71粗车循环N60G0G42X15.2Z2F0.15；循环开始N70G1Z0N80X16.38Z-1.39N90Z-6N100X16.991N110Z-21.5N120X18N130Z-23；循环结束N140G0X19Z2N150G96S80N160G70P60Q130；G70精车循环N170G0X100Z150N180T0202；换钻头N190G0G40X0Z25S500F0.2；钻孔开始,取消刀补N200G1Z-10N210G0Z2N220G1Z-20N230G0Z0N240Z-18N250G1Z-35N260G0Z0N270Z-33N272Z-50N274G0Z0N276Z-48N280G1Z-62N290P1N300G0Z2；钻孔结束N310G0X100Z150N320T0303；换铰刀N330G0X0Z5N340G1Z-62；铰孔N350P1N360G0Z2N370G0X100Z150N380T0404；换镗刀N390S1500F0.2N400G0G43X13.5Z-0.433；刀补N405G1X12.5Z-0.433；镗孔N410Z-13N420X8N430G0Z2N440X100Z150N450T0505；换内切槽刀N460G0G40S60X8Z5F0.1N470Z-27.65N480G1X11.1；切内槽N490G0X8N500W2N510G1X11.1N520G0X8N530Z-24.93N540G1X9N550X11.65Z-25.65N555Z-27.65N560X9Z-28.37N570G0X8N580Z5N590G0X100Z150N600M30;程序结束五、MASTERCAM仿真1.刀具轨迹图:2.加工后的轮廓图:3.加工后立体图:4.PRO/E制作的三维图:5.MASTERCAM导出的加工程序:%O0000G21(PROGRAMNAME-MYMASTER22DATE=DD-MM-YY-20-11-11TIME=HH:MM-16:31)(TOOL-1OFFSET-1)(LFACEODROUGHRIGHT-80DEG.INSERT-CNMG120408)G0T0101G97S3600M13G0G54X26.Z.5G50S3600G96S295G99G1X-1.6F.2G0Z2.5X26.Z0.G1X-1.6G0Z2.G28U0.W0.M05T0100M01(TOOL-2OFFSET-2)(LROUGHODFINISHRIGHT-35DEG.INSERT-VNMG160408)G0T0202G97S3600M13G0G54X18.666Z.5G50S3600G96S295G1Z0.F.3Z-35.436G3X18.687Z-35.6R1.3G1Z-37.845X19.4Z-59.283Z-59.3Z-60.5Z-110.127X22.X24.828Z-108.713G0X26.666Z-35.246X19.394G1X18.687Z-35.6G2X18.4Z-35.006R1.3F.1G1Z-23.3F.3Z-22.3G2X17.4Z-21.434R1.F.1G1Z-6.8F.3G2X17.2Z-6.364R1.F.1G1Z-2.186F.3G2X16.932Z-1.686R1.F.1G1X15.332Z-.3Z0.F.3X18.16Z1.414G0X19.4Z-22.946X19.107G1X18.4Z-23.3G3X17.712Z-24.055R1.F.1G1X17.2Z-24.277Z-30.209F.3Z-34.425G3X18.687Z-35.6R1.3G1X21.515Z-34.186G0X22.515Z-35.246X19.394G1X18.687Z-35.6G3X18.622Z-35.889R1.3F.1G1X19.087Z-49.874F.3X21.915Z-48.459G0X22.915Z-60.146X20.107G1X19.4Z-60.5G3X18.712Z-61.255R1.F.1G1X16.4Z-62.26Z-62.8F.3Z-66.3Z-68.156G3X15.733Z-68.901R1.F.1G1Z-110.127F.3X19.8X22.628Z-108.713G0Z-109.773X19.093G1X19.8Z-110.127X12.067F.1Z-86.434F.3X12.279Z-86.142G2X12.4Z-85.8R1.G1Z-77.3Z-76.2Z-72.9Z-70.35X15.712Z-68.91G2X16.133Z-68.655R1.G1X18.962Z-67.24G0Z-68.525X17.099G1X16.133Z-68.655G3X15.712Z-68.91R1.F.1G1X12.4Z-70.35Z-72.9F.3Z-76.2Z-77.3Z-85.8G3X12.279Z-86.142R1.F.1G1X10.641Z-88.392G2X10.4Z-89.076R2.G1Z-104.223F.3G3X9.712Z-104.977R1.F.1G1X8.4Z-105.548Z-110.127F.3X12.467X15.295Z-108.713G0X22.Z.083X15.244G1X14.986Z-.4X16.586Z-1.786G3X16.8Z-2.186R.8G1Z-6.413G3X17.Z-6.8R.8G1Z-21.558G3X18.Z-22.3R.8G1Z-23.3G3X17.45Z-23.904R.8G1X16.8Z-24.186Z-30.209Z-34.559G3X18.287Z-35.6R1.1X18.221Z-35.867R1.1G1X19.Z-59.287Z-59.3Z-60.5G3X18.45Z-61.104R.8G1X16.Z-62.169Z-62.8Z-66.3Z-68.156G3X15.45Z-68.759R.8G1X12.Z-70.259Z-72.9Z-76.2Z-77.3Z-85.8G3X11.904Z-86.074R.8G1X10.265Z-88.324G2X10.Z-89.076R2.2G1Z-104.223G3X9.45Z-104.826R.8G1X8.Z-105.457Z-110.327X10.828Z-108.913G0X21.6G28U0.W0.M05T0200M01(TOOL-4OFFSET-4)(LFINISHODGROOVECENTER-WIDEINSERT-N151.2-600-4E)G0T0404G97S1592M13G0G54X23.Z-44.966G50S3600G96S115G1X14.3F.1G0X23.Z-46.963G1X14.3X14.699Z-46.763G0X23.Z-42.969G1X14.3X14.699Z-43.169G0X23.Z-48.96G1X14.3X14.699Z-48.76G0X23.Z-40.972G1X14.3X14.699Z-41.172G0X23.Z-50.956G1X14.708X15.107Z-50.757G0X23.Z-38.975G1X14.382X14.781Z-39.175G0X23.Z-52.953G1X17.014X17.413Z-52.753G0X23.Z-36.979G1X16.423X16.822Z-37.178G0X23.Z-33.474X21.022G1X18.193Z-34.888X14.251Z-38.595G2X13.9Z-39.299R1.5G1Z-50.255G2X14.302Z-51.005R1.5G1X18.973Z-55.05G0X21.802G28U0.W0.M05T0400M01(TOOL-3OFFSET-3)(LFINISHODGROOVECENTER-NARROWINSERT-N151.2-185-20-5G)G0T0303G97S1695M13G0G54X21.6Z-76.3G50S3600G96S115X16.G1X11.5F.1G0X16.Z-77.914X14.828G1X12.Z-76.5X11.5G0X14.828Z-74.986G1X12.Z-76.4X11.5Z-76.5G0X14.828X21.6G28U0.W0.M05T0300M01(TOOL-4OFFSET-4)(LFINISHODGROOVECENTER-WIDEINSERT-N151.2-600-4E)G0T0404G97S1592M13G0G54X23.Z-60.5G50S3600G96S115G1X16.4F.1G0X23.Z-60.G1X16.4X16.5Z-60.05G0X23.Z-59.9G1X16.4X16.5Z-59.95G0X23.Z-61.G1X16.4X16.5Z-60.95G0X23.Z-61.5G1X16.4X16.5Z-61.45G0X23.Z-57.086X21.828G1X19.Z-58.5Z-59.6G3X18.8Z-59.7R.1G1X16.Z-61.9G3X15.93Z-61.976R.1G0X18.758X21.6G28U0.W0.M05T0400M01(TOOL-3OFFSET-3)(LFINISHODGROOVECENTER-NARROWINSERT-N151.2-185-20-5G)G0T0303G97S1642M13G0G54X22.287Z-17.967G50S3600G96S115G1X17.4F.1G0X22.287Z-18.067G1X17.4X17.42Z-18.057G0X22.287Z-17.868G1X17.4X17.42Z-17.878G0X22.287Z-18.167G1X17.4X17.42Z-18.157G0X22.287Z-17.768G1X17.4X17.42Z-17.778G0X22.287Z-18.267G1X17.4X17.42Z-18.257G0X22.287Z-17.668G1X17.4X17.42Z-17.678G0X22.287Z-18.367G1X17.4X17.42Z-18.357G0X22.287Z-17.568G1X17.4X17.42Z-17.578G0X22.287Z-18.466G1X17.4X17.42Z-18.456G0X22.287Z-17.468G1X17.4X17.42Z-17.478G0X22.287Z-18.566G1X17.4X17.42Z-18.556G0X22.287Z-17.368G1X17.4X17.42Z-17.378G0X22.287Z-18.666G1X17.4X17.42Z-18.656G0X22.287Z-17.269G1X17.4X17.42Z-17.279G0X22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